EP1023189A1

EP1023189A1 - Prefabricated roofing element

Info

Publication number: EP1023189A1
Application number: EP98949044A
Authority: EP
Inventors: Alain Cocault
Original assignee: Sciel - Creation Integrale Pour Entreprise Et Loisirs - Ste
Current assignee: Sciel - Creation Integrale Pour Entreprise Et Loisirs - Ste
Priority date: 1997-10-14
Filing date: 1998-10-13
Publication date: 2000-08-02
Anticipated expiration: 2018-10-13
Also published as: DE69803086D1; ES2170527T3; FR2769653B1; US6251511B1; ATE211078T1; FR2769653A1; CA2304026A1; EP1023189B1; DE69803086T2; WO1999019154A1

Abstract

A prefabricated roofing element in the form of a laminate consisting from its inner surface towards its outer surface exposed to poor weather conditions, of at least a first continuous layer constituting an element core based on a thermosetting binder and reinforcing materials, of a second continuous protective coating layer, consisting of a mixture of at least a synthetic resin, a constituent staining in its volume the resin and a catalyst. The roof cover element is characterized in that it further comprises at least a third discontinuous layer of paint unevenly distributed on the surface of the second layer and consisting of materials immiscible with the second layer constituents to form spots at the second layer surface.

Description

Prefabricated roofing element

The present invention relates to a prefabricated roofing element in the form of a laminate.

It relates more particularly to a roof covering element composed of its internal face towards its external face exposed to the weather of at least one first continuous layer constituting the core of said element and formed of a mixture of at least one binder and of reinforcing materials, of a second continuous layer of an ultraviolet and weather protection product called gelcoat, consisting of the mixture of at least one synthetic resin, preferably thermosetting, such as a polyester resin, of a constituent mass dyeing said resin and a catalyst.

Interlocking tiles have been widely used in multiple ways for roofing dwellings. These tiles generally made of baked clay make it possible to obtain very waterproof and resistant but heavy covers and very exposed to breakage, in particular in the event of hail. So we saw appear on the market, for roofing, synthetic sheets which have been printed in the shape of interlocking tiles. These light, weather resistant plates, however, did not achieve the expected commercial success essentially for two reasons. On the one hand, the use of asbestos-based materials, such as fiber cement (registered trademark), poses risks to the health of users. On the other hand, these plates offer a poor imitation of the natural appearance of traditional products, such as tiles and slates, this poor imitation is further accompanied by a rapid degradation over time of this aspect.

Solutions concerning the first problem exposed above were found and are exposed in particular in the French patents FR-A-2,451,429 and FR-A-2,522,348. The roof elements described in these patents are obtained by the use of reinforced resins free from risks to the health of the occupants of a dwelling. However, the composition of such roofing elements and the manufacturing methods used are not satisfactory in terms of appearance of the product and in terms of resistance over time of this product.

Patent FR-A-2,522,348 recommends, to imitate the appearance of traditional products, the use of aggregates which pose problems of homogenization of the mixture and distribution of the aggregates on the surface of the finished product.

Patent FR-A-2,451,429 recommends, for its part, the use of a tinted gelcoat having a rough appearance capable of causing a certain number of drawbacks such as the retention of dust and, the development of foams in the level of roughness.

An object of the present invention is to overcome the aforementioned drawbacks by proposing a prefab roofing element with a very similar appearance. traditional products, such as tiles and slates, which age well over time and with water and which can be manufactured using an industrial process.

Another object of the present invention is to provide a method of manufacturing a prefabricated roofing element which is easy to implement and which enables the finished product to be obtained quickly.

To this end, the subject of the invention is a prefabricated roofing element in the form of a laminate composed of its internal face towards its external face exposed to the weather, of at least one first continuous layer constituting the core of said element and formed from a mixture of at least one thermosetting binder and reinforcing materials, from a second continuous layer of a protective coating to ultraviolet and weathering called gelcoat consisting of the mixture of at least one synthetic resin, preferably thermosetting, such as a polyester resin, of a tinting component in the mass of said resin and of a catalyst, this element being characterized in that it also comprises, at least a third discontinuous layer of a paint irregularly distributed on the surface of the second layer and composed of materials immiscible with the constituents of the second layer to form on the surface of the second layer of tasks giving, in cooperation with the second layer of said element, an appearance imitating the appearance of traditional materials such as slates or tiles.

According to a preferred embodiment of the invention, the third layer of the covering element consists of a paint based essentially on a thermoplastic resin chosen from the group of polyurethane, acrylic resins or two-component resins acrylic-urethane, a catalyst capable of promoting the polymerization of said resin and pigments. The subject of the invention is also a method of manufacturing a prefabricated roofing element characterized in that, by spraying, it is deposited in the form of irregular droplets on the surface of the molding cavity of a mold of corresponding shape. in the form of a covering portion to be reproduced, a paint based on a thermoplastic resin to form the so-called upper layer of a laminated roofing covering element, in that this layer is covered after hardening a second continuous layer of a mixture based on a tinted thermosetting resin immiscible with the paint of the upper layer and in that, after hardening of this second layer, a layer capable of forming the core of said element is applied , this layer consisting of at least one reinforcing material and a binder. ^'

The invention will be more particularly described below on the basis of an exemplary embodiment of the invention.

The roof covering element, object of the invention, is in the form of a part whose conformation depends on the traditional material to be imitated. This conformation is generally obtained by molding. Thus, in the case of a covering element imitating the tile, the shaped part imitates by imprints several successive rows of elements such as tiles, the edges of this part being shaped to allow assembly by covering of said edges during the side by side positioning of two identical parts on a roof frame.

This roofing element is in the form of a laminate composed of at least three layers. The first layer also called the core of said element and constituting the internal face of said element is formed of a mixture of at least one thermosetting binder and reinforcing materials. Mention may be made, as thermosetting binder, of polyester, phenolic resins, furanic, epoxy or other. However, in a preferred embodiment of this core, it consists of a mixture of at least one thermosetting resin tinted in the mass, such as a tinted polyester resin, and glass fibers, the fibers of glasses being present in said mixture in a proportion in the range [20-30%] by weight. By way of example, for this first layer, an unsaturated polyester resin diluted with styrene and methyl methacrylate can be used. This resin is accelerated by means of an accelerator, such as a 6% solution of cobalt octoate, then hardened by means of a catalyst, such as a peroxide of either methyl ethyl ketone or acetyl acetone ( 2-4- pentanedione). Such a resin is commercially available and sold by Sté Reichhold under the reference Dion FR 7722.00. Other pre-accelerated unsaturated polyester resins such as Viapal VUP 4754 BEMT resin manufactured by Vianova Resins can be used.

The second layer of this element is a continuous layer of a protective coating, called gelcoat, consisting of the mixture of at least one synthetic resin, preferably thermosetting, such as a polyester resin, of a tinting component in the mass. said resin, and a catalyst. The thickness of this second layer is generally in the range [0.3-0.5 mm]. In addition, the constituents of the first and second layers used for dyeing said layers are chosen such that the shade of the first layer is identical to that of the second layer. As a tinting component in the bulk of said resin, mention may be made of rutile titanium treated with chlorine. More generally, the colors of the core and of the second layer are obtained from bases of white, blue, or black for a covering element imitating slate and from bases of yellow, red, orange for a cover element imitating the tile. In other words, the final colors of the core and the second layer may be for a cover element imitating slate type RAL 7015, 7016 or 7021 and for a cover element imitating tile type RAL 2001 to 2010.

This laminate further comprises at least a third layer constituting the external face exposed to the weather of said element. This third layer is a discontinuous layer of a paint distributed unevenly on the surface of the second layer. This third layer is composed of materials immiscible with the constituents of the second layer to form on the surface of the second layer tasks conferring on said element, in cooperation with the second layer, an appearance imitating that of traditional materials such as slates or tiles. This third layer is preferably made of a paint, essentially based on a resin chosen from the group of polyurethane, acrylic, acrylic-urethane resins, a catalyst capable of promoting the polymerization of said resin and color pigments. black.

This constituent paint of the third layer covers at most 15% of the surface of the second layer. This third layer is applied to the surface of the second layer in the form of droplets by spraying. The details of this projection will be described below. Generally, the resin of this third layer consists of a base preferably belonging to the family of hydroxylated acrylic compounds and / or compounds based on urethane and of a diluent consisting of an organic solvent, such as acetate. of 2-butoxyethyl, ethyl acetate or the like. The catalyst generally belongs to the family of polyisocyanates. Thus as a base, one can use a Deltron HS base except 914 manufactured by PPG industries SA and consisting essentially of isocyanate prepolymers (N = C = 0 free) and organic solvents. As a diluent, one can use the diluent D807 S0741 from PPG Industries SA and as a catalyst the hardener D802 STP of this same company. The color of the paint varies according to the desired aging aspect.

Thus, in view of what has just been specified above, a typical composition of a roofing element can be defined as follows:

Soul of the element:

Accelerator: 6% cobalt octoate: 0.5% total weight of the resin

Resin: Mi-Dion FR 7722.00 (Reichhold) = 75-85% by weight M4-Viapam VUP 4754 Bemt (Vianova Resins) = 65.75% by weight

Catalyst: methyl ethyl ketone peroxide: 10-35% of the total weight of the resin

Glass fibers = 15-35% by weight

pigments: rutile titanium treated with chlorine

Gelcoat

Pigments = rutile titanium treated with chlorine

Accelerator = 6% cobalt octoate = 0.5% of the total weight of the resin

Catalyst = methyl ethyl ketone peroxide = 10-35% of the total weight of the resin

Resin = Medogel M series (medoc paints) or gelcoat

NI 11 (Reichhold): 300 g - 600 g / m ² 3rd layer

Painting: base deltron HS except 914 (PPG industries SA): 2 volumes

Thinner: D870 S0741 (PPG industries SA): 2 volumes

Catalyst: D802 hardener STD (PPG industries SA): 1 volume

To obtain such a roof covering element, the procedure is generally as follows. First of all, a mold is produced, generally made of synthetic material to allow obtaining shapes conforming to those of a traditional cover part. On the surface of this mold corresponding to the bottom of the molding cavity, a spray-on, in the form of irregular droplets, deposits a polyurethane or acrylic paint or two-component acrylic-urethane to form the so-called upper layer of the covering element laminate roofing. This projection is carried out by means of pneumatic gravity guns. We choose a large flow of paint and a low air pressure to obtain during the fall by gravity of the paint irregular projections.

Generally, before this paint deposition step, at least one mold release agent is applied to the surface of the molding cavity. At least one of the release agents is constituted by polyvinyl alcohol to give a matt appearance to the covering element once it has been produced. In addition to polyvinyl alcohol, it is possible to use a release agent chosen from the following compounds:

- liquid or paste wax type FK made by paints from Médoc SA,

semi-permanent agent type moulex 2000 made by painting the Médoc. This release agent (s) are generally also applied with a pneumatic gravity gun. The catalyst, capable of promoting the drying of the paint, is sprayed simultaneously with the paint, the catalyst / paint mixture having been produced beforehand. This spraying operation is carried out inside a heated tunnel so as to activate the polymerization. Hot air is blown through nozzles in the tunnel. These hot air inlets participate in obtaining irregular projections of the paint.

Once this paint removal operation has been carried out, the mold is brought to the gelcoat application station. This application is again made with a spray gun. The mold continues to move inside the heated tunnel to receive a layer intended to constitute the core of said covering element. This layer consists of glass fibers and a mass-dyed polymerizable resin. This is also applied by spray gun. The presence of glass fibers requires a subsequent boiling of this layer. This debubbling can be carried out by means, for example, of a load of steel balls placed inside a polyethylene envelope, the assembly being applied to the surface to be debubbed.

Once the bubble removal operation is complete, the part is extracted from the production installation and can be stored for mounting on a frame. During its manufacture, it is preferable that this part is exposed to a temperature of the order of 30 ° C-60 ° C to accelerate all polymerizations.

In the case of the manufacture of slates, the mold is during the first stage of projection of a paint kept inclined to give the spots obtained from the projection of paint a casting appearance, better imitating the slate.

Claims

1. Prefabricated roofing element in the form of a laminate composed of its internal face towards its external face exposed to the weather, of at least one first continuous layer constituting the core of said element and formed of a mixture of at least one thermosetting binder and reinforcing materials, of a second continuous layer of a protective coating, called gelcoat, consisting of the mixture of at least one synthetic resin, preferably thermosetting, such as a polyester resin, of a constituent tinting in the mass said resin and of a catalyst, characterized in that the covering element further comprises at least a third discontinuous layer of a paint distributed irregularly on the surface of the second layer and composed of materials immiscible with the constituents of the second layer to form on the surface of the second layer tasks conferring in () cooperation with the second layer of said element an appearance imitating that of traditional materials, such as slates or tiles.

2. Prefabricated roofing element according to claim 1, characterized in that the core of said element consists of a mixture of at least one mass-dyed thermosetting resin, such as a dyed polyester resin and glass fibers, the glass fibers being 0 present in said mixture in a proportion comprised in the range [20-30%] by weight.

3. Roof covering element according to one of claims 1 and 2, 5 characterized in that the thickness of the second layer is in the range [0.3-0.5 mm].

4. Prefabricated roofing element according to one of claims 1 to 3, characterized in that the constituents of the first layer and of the second layer used for dyeing said layers are chosen such that the color of the first layer is identical to that of the second layer.

5. Element according to one of claims 1 to 4, characterized in that the third layer consists of a paint based essentially on a resin chosen from the group of polyurethane, acrylic, acrylic-urethane resins, a catalyst capable of promoting the polymerization of said resin and of pigments.

6. Element according to one of claims 1 to 5, characterized in that the paint constituting the third layer covers at most 15% of the surface of the second layer.

7. Element according to one of claims 1 to 6, characterized in that the third layer is applied to the surface of the second layer in the form of droplets by spraying.

8. Method for manufacturing a prefabricated roofing element in accordance with one of claims 1 to

7, characterized in that by spraying in the form of irregular droplets on the surface of the molding cavity of a mold of shape corresponding to the shape of a cover portion to be reproduced, a paint based on a thermoplastic resin to form the so-called upper layer of a laminated roofing element, in that, after hardening, this layer is covered with a second continuous layer of a mixture based on a non-miscible tinted thermosetting resin with the paint of the top layer and in what we apply after hardening of this second layer, a layer capable of forming the core of said element, this layer consisting of at least one reinforcing material and a binder.

9. Method according to claim 8, characterized in that prior to the deposition inside the mold of the paint constituting the upper layer, the molding cavity is coated with at least one release agent consisting of polyvinyl alcohol to give a matt appearance to the cover element.